Tesla has reportedly submitted for a patent for a new, more effective cooling process aimed at increasing the strength, rigidity, and energy absorption of aluminium alloy components. The patent entitled “System and Method for Facilitating Pulsed Spray Quench of Extruded Objects” describes a new quenching process that would involve a multi-way spray nozzle system to cool extruded aluminium with an atomised spray of liquid.
“A system includes a billet die at a proximal end configured to accept a billet and form an extrudate, a quench chamber located adjacent to the billet die for receiving the extrudate and comprising at least one pulsed width modulation (PWM) atomizing spray nozzle and a control module in communication with the at least one PWM atomizing spray nozzle and configured to independently control a liquid pressure, a gas pressure, a spray frequency, a duty cycle and flow rate of each at least one PWM atomizing spray nozzle,” reads the patent abstract.
Tesla in its patent also stated that it uses 6XXX alloys for its vehicle parts such as the front and rear bumpers, side and back steps, and knee bolsters of a car. After these parts are extruded, they enter a quenching process, which Tesla plans to upgrade to a multi-way spraying system to cool extruded aluminium parts. Tesla currently uses a quenching process that involves cooling the extruded alloys by soaking the vehicle parts in water. Tesla’s patent has identified some of the adverse effects in this process, known as ‘quick cooling’. The process, according to Tesla, can lead to deformation and warping of metal parts, and can also change things chemically.
The new, updated quenching process would involve spraying extruded metals at varying rates depending on the size of the vehicle part, stated Tesla in its patent.
Two pyrometers, which would be responsible for maintaining the metal’s temperature throughout the quenching process, would be placed at both the proximal and distal ends of the quench chamber. The pyrometers would communicate with the system to ensure proper cool temperatures, making sure the extruded aluminium does not cool down too quickly until the Magnesium silicide is set. Pyrometers would also monitor spray frequency, liquid pressure, gas pressure, and flow rate to ensure maximum strength to the alloys.
Tesla’s recognition of the flaws in the quick cooling process indicates the company's realisation that the strength of a car frame is possible to improve with a more efficient cooling technique.
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